SPES Underwater Eddy Current Proximity Sensor User s Manual P/N M2A-107

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1 SPES -108 Underwater Eddy Current Proximity Sensor User s Manual P/N M2A-107

2 Safety Information The following manual contains information and warnings. They must be followed in order to keep the instrument in a working condition and ensure safe operation. Safety and Electrical Symbols Safety Precautions Warning - Danger - Identifies conditions or practices that could cause physical harm or death. Caution - Identifies conditions or practices that could result in a permanent loss of data or damage the measuring chain and/or other equipment to which it is connected. Important Information - Identifies important information, hints, and tips that must be read and applied. Shield connection location Warning - Danger Caution To use the described product correctly and safely, read and follow all safety instructions or warnings that appear throughout this manual. This product in intended to be used by qualified operators and maintenance personnel who recognize shock hazards and are familiar with the safety precautions required to avoid possible injury. Read and follow all installation, operation, and maintenance information before using this product. Install and use this product only as specified in this manual or the protection provided by this product might be impaired. When in doubt that safety protection has been impaired, make this product inoperative and secure it against any unintended operation. The VibroSystM logo, ZOOM, and SPES are registered trademarks or trademarks of VibroSystM Inc. This manual is provided solely for guidance. VibrosystM Inc. takes no responsibility or liability for any damage caused by accidents, improper installation or misuse. Liability is limited to the repair and/or replacement of defective products. VibroSystM Inc Jacques-Cartier E. Blvd, Longueuil, QC, Canada J4N 1L7 Phone: U.S. Toll-free Line: techsupp@vibrosystm.com 2 SPES User s Manual 2016 VibroSystM Inc. All rights reserved

3 TABLE OF CONTENTS 1. SPES-108 SENSOR OVERVIEW Description Main Unit Interventions SENSOR OPERATION Connecting the SPES-108 Sensor Assessing the Actual Sensitivity Measuring Current Output (Iout) and Corresponding Distance Taking a Measurement with the Sensor Installed Calculating the Sensitivity Adjustment Through the ZOOM Configuration Software SENSOR INSTALLATION OVERVIEW Sensor Positioning Positioning in a Kaplan Turbine Positioning in a Francis Turbine Preparing the Chamber for the Sensor Installing the Sensor APPENDIX: TEMPLATE FOR RECORDING DISTANCE VALUES VS I out SPES User s Manual 3

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5 1. SPES-108 SENSOR OVERVIEW 1.1 Description The SPES-108 proximity sensor is designed to measure the relative distance of an underwater metallic target surface. It is usually used to measure blade tip clearance in Kaplan turbines as well as runner band clearance in Francis turbines. The sensor can sustain high levels of underwater pressure and is equipped with built-in conditioning circuitry allowing it to be directly connected to processing instrumentation. The SPES-108 covers a 0 to 8 mm [0 to 315 mils] measuring range. SPES-108 Underwater Proximity Sensor SPES-108 Sensor Sensing Face Integral Cable Tightening Pins 1.2 Main Unit Interventions A hole must be bored in the throat ring or bottom ring. Integral cables must be routed and protected from the sensor all the way to the acquisition unit. Caution Installation guidelines and connection instructions must be thoroughly followed to ensure a safe and proper operation. In order to complete the commissioning, VibroSystM must be contacted when Section 2.2 (Assessing the actual sensitivity) is reached. SPES User s Manual 5

6 2. SENSOR OPERATION 2.1 Connecting the SPES-108 Sensor The SPES-108 sensor must first be connected to a 24VDC power supply and a receiving instrument. It is important to confirm the sensor s functionality before proceeding with a permanent installation. Integral Cable Color Code Designation Specifications Load at current output: 500 Ω max. Load at voltage output: 10 kω min. Red Power Supply +24 VDC White Current Output ma (proportional to sensor s full range) Blue Common 0 V Yellow Voltage Output 2-10 V (proportional to sensor s full range) Important Information The integral cable shield on the SPES-108 is not connected to the sensor side. It must always be connected to the ground on the instrumentation side. 6 SPES User s Manual

7 2.2 Assessing the Actual Sensitivity The SPES-108 proximity sensor is calibrated to produce a linearized output based on an FE360 steel target. Because the sensitivity of eddy current sensors is affected by the target s material, the actual sensitivity must be determined. Important Information Failure to correctly assess and compensate the sensitivity will result in incorrect measurement results as presented in the illustration below. SPES-108 Calculated Distance vs Sensor Current Output Real Distance vs Sensor Output Incorrect Calculated Distance (Without Compensation) Correct Calculated Distance (With Compensation) SPES User s Manual 7

8 2.2.1 Measuring Current Output (I out ) and the Corresponding Distance To assess the sensor s actual sensitivity, physical distance and current measurements must first be taken using a target made of the same material as the real target. Minimum dimensions for the target are: 75mm x 75mm x 2mm [3" x 3" x 1/16"]. Proceed as follows: Fill the table with measurements (distance vs current), equally distributed on the full current scale. Add non- metallic spacers between the sensor s tip and the target until I out max. is approximately reached. Note down the current value and the distance (total spacer thickness) in the table. Gradually remove spacers to approximately reach the next I out level and again, write down the current value and distance. Repeat until the table is filled. The last I out value is measured without spacers (0mm), with the sensor s tip placed directly against the target. Recorded Distance Values vs I out for SPES-108 Important Information Section must be completed BEFORE installing the sensor. Sections 2.2.2, 2.2.3, and must be completed AFTER installing the sensor. In the examples below, calculations are in metric format. All distances may also be measured in inches with the resulting values used in the same formulas. Ideal level of I out (ma) Measured I out (ma) Measured distance (mm) 0 Example of Recorded Distance Values vs I out for SPES-108 I op = 11.9 ma I out B I out A Measured I out (ma) Measured distance (mm) d B d A 8 SPES User s Manual

9 2.2.2 Taking a Measurement with the Sensor Installed With the sensor now installed, take a measurement and note the real operating current (I op ). Important Information For Kaplan turbines, I op has to be measured with the blade positioned in front of the sensor. Example with SPES-108: I op = 11.9 ma Calculating the Sensitivity Select two points in the table on either side of the value closest to I op. These two points (A & B) will be used to define the linear equation. The selected points should be at an equal distance from I op. Ideally, point A should be at I op ma and point B at I op ma. For example, if I op = 11.9 ma: Point A: I op ma= 9.4 ma (closest correspondence in the table: I out A = 10.6 ma, d A = 2.3 mm) Point B: I op ma=14.4 ma (closest correspondence in the table: I out B = 15.5 ma, d B = 4.65 mm) a) Using selected points A and B, calculate «m» (the sensitivity or gain). Example m = d B - d A I outb - I outa m = = 0.48 b) Using the formula below, calculate «b» (the y-intercept) of the linear equation. c) The equation to calculate the compensated distance corresponding to the sensor current output is the following: d C = (m x I out ) + b Example with values closest to I op b = d - (m x I out ) b = (0.48 x 15.5) = mm Where: d C is the calculated distance (in mm) d) Verify the «m» and «b» calculated values by applying the following formula on the measured value between the A and B coordinates: for I out to equal 13 ma, verify that d C = 3.35 mm (± 10% of range): d C = (0.48 x 13) = 3.45 mm SPES User s Manual 9

10 2.2.4 Adjustment Through the ZOOM Configuration Software Proceed with the final adjustment through the ZOOM Configuration software. Select Sensor Configuration, and in the Range tab of the dialog window, enter the Maximum and Minimum values of the Raw output range. Formulas for Adjusting the Raw Output Range Maximum = (m x 20 ma) + b Minimum = (m x 4 ma) + b Note: In the Trending and alarm range section, the Maximum and Minimum values must be within the limits of the Raw output range. Example with Calculated Values Trending and alarm range adjusted to the limits of the raw output range Maximum = (0.48 x 20 ma) Minimum = (0.48 x 4 ma) SPES User s Manual

11 3. SENSOR INSTALLATION OVERVIEW 3.1 Sensor Positioning Before deciding where to install the sensor, consider the following: The sensor s sensing face must face the target. The maximum cable length (integral cable + extension) must be established. From the SPES-108 sensor to the acquisition unit, the maximum distance is 300 m [984 ft] for the current output and 100 m [328 ft] for the voltage output. The cable and the back of the sensor must be protected against debris and turbulence. The submersible cable must be firmly secured to prevent premature aging. 3.2 Positioning in a Kaplan Turbine VibroSystM recommends using one SPES-108 sensor per turbine blade. If the turbine is in place, install the sensors between the blades to avoid damage. Sensors must be equally distributed around the unit. All sensors must be aligned at exactly the same vertical height, corresponding to the center of the blades (or the blades rotation axis, if applicable). Kaplan Turbine Sensor Positioning Caution The SPES-108 sensor must be connected correctly with the cable well protected against any sort of mechanical damage. Important Information VibroSystM recommends relying on the services of a trained technician for supervising the installation of these proximity sensors and finalizing configuration of the ZOOM Software. Side View Throat Ring Top View Sensor 1 Throat Ring Blade Center Sensor 5 Blade Rotation Axis (if applicable) Sensor 2 Sensor 4 SPES-108 Sensor Sensor 3 PV120528B Caution The SPES-108 and the blade s angular positions in relation to the synchronization probe must be established. This information will be required during configuration in the ZOOM software. SPES User s Manual 11

12 3.3 Positioning in a Francis Turbine To monitor turbine displacement in a Francis turbine installation, sensors must be installed at a 90-degree angle from each other, facing the runner band. The sensor s angular position in relation to the synchronization sensor must also be determined. Francis Turbine Sensor Positioning Sensor 1 90 Typ. Bottom Ring Sensor 4 Sensor 2 SPES-108 Sensor Sensor 3 SIDE VIEW TOP VIEW PV050313A 12 SPES User s Manual

13 3.4 Preparing the Chamber for the Sensor The chamber must be perpendicular to the throat ring or bottom ring. When preparing the chamber for the sensor, the precision of the boring is critical for a tight fit installation. Important Information In order to get the sensor properly secured inside the chamber, the drilling must be concentric. The following installation guidelines are for installation on a bottom ring. Chamber Preparation 1. Drill the chamber into the ring. Fitting the Sensor Inside the Chamber 2. Place a rod between the tightening pins, hold it firmly with a pair of pliers and turn clockwise to temporarily insert the sensor inside the chamber. Make sure the sensor can be easily inserted and fits perfectly inside the chamber. SPES User s Manual 13

14 3.5 Installing the Sensor Caution To preserve the sensor s long-term waterproofness, do not install it if the integral cable s outer sheathing shows any signs of damage. Thread Sealant Application APPLY SEALANT HERE 1. To ensure waterproofness, apply sealant as pointed out in the illustration. 2. Place a rod between the tightening pins, hold it firmly with a pair of pliers and turn clockwise until the sensor is firmly secured inside the chamber. Make sure that it fits perfectly inside the chamber. 3. Once the SPES-108 sensor is firmly secured, remove the tightening pins. 4. Let the sealant dry according to manufacturer specifications. APPLY SEALANT HERE 14 SPES User s Manual

15 APPENDIX: TEMPLATE FOR RECORDING DISTANCE VALUES VS I out Unit no.: Sensor S/N: Position: Measured I out (ma) Measured distance (mm) 0 Unit no.: Sensor S/N: Position: Measured I out (ma) Measured distance (mm) 0 Unit no.: Sensor S/N: Position: Measured I out (ma) Measured distance (mm) 0 Unit no.: Sensor S/N: Position: Measured I out (ma) Measured distance (mm) 0 Unit no.: Sensor S/N: Position: Measured I out (ma) Measured distance (mm) 0 Unit no.: Sensor S/N: Position: Measured I out (ma) Measured distance (mm) 0 SPES User s Manual 15

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SPES Underwater Eddy Current Proximity Sensor User s Manual P/N M3A-103

SPES Underwater Eddy Current Proximity Sensor User s Manual P/N M3A-103 SPES -117 Underwater Eddy Current Proximity Sensor User s Manual P/N 9431-09M3A-103 Safety Information The following manual contains information and warnings. They must be followed in order to keep the